Dynamic balance method and system for virtual counterweight of rotating machinery based on multi-standard dynamic compliance

Abstract

The invention discloses a rotating machinery virtual counterweight dynamic balance method based on multi-standard dynamic compliance, and the method specifically comprises the following steps: collecting a rotor vibration signal and a phase signal, and calculating the residual unbalance through a formula; inputting the equipment metadata and the real-time working condition into a rule engine, and automatically selecting and recommending a target standard from a standard library by the rule engine; after manual confirmation, the permissible unbalance Uperm or the vibration threshold Vperm is locked; a counterweight scheme is rendered in a three-dimensional visualization engine, and a finite element API is called in real time to check sigma max; when sigma < max > is smaller than or equal to 0.8 sigma < yield > and the standard reaching degree displayed by the compliance progress bar is larger than or equal to 100%, a balance weight implementation scheme is determined; the system outputs a balance weight hole drilling position, a bolt specification, a torque and a hammerhead / impeller replacement list, and pushes the list to the MES through OPCUA / REST API; after construction, vibration is automatically measured and corrected, and a closed loop is formed.

Description

Technical Field

[0001] This invention relates to a method and system for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance. Background Technology

[0002] Various rotating machinery develops residual imbalances due to wear, impact, or material inhomogeneity during long-term operation, leading to excessive vibration, bearing overload, and unplanned downtime. Traditional on-site dynamic balancing relies on manual "trial weight-trial run" cycles and is mostly limited to a single standard (such as ISO 1940 G6.3). Existing monitoring or simulation patents often focus on vibration diagnosis or counterweight design, and have not yet built an integrated system that combines "multi-standard dynamic tolerance judgment + intelligent multi-objective optimization + virtual simulation + structural safety verification + human-machine interaction closed loop," nor do they provide unified adaptation to flexible rotors and industry standards (API, ISO 10816, etc.). Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a method and system for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance.

[0004] To solve the above technical problems, the technical solution of the present invention is as follows:

[0005] A method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance includes the following steps:

[0006] The rotor vibration signal and phase signal are collected, and the result is obtained through formula U. r =k·A rms / ω 2 Calculate the residual unbalance U r , where k is determined by calibration experiments, and the phase signal is obtained through a photoelectric / magnetic grating encoder;

[0007] Input the equipment metadata and real-time operating conditions into the rule engine, and the rule engine will automatically select and recommend target standards from the standard library;

[0008] After manual confirmation, the permissible imbalance U is locked. perm Or vibration threshold V perm ;

[0009] When U r >U perm Or the effective value of vibration A rms >V perm At that time, the counterweight mass Δm was generated based on the improved NSGA-II multi-objective optimization algorithm. i and phase φ i The objective function is J = w1·(U r / U prem )+w2·ΣΔmi Where w1:w2=0.7:0.3, the constraints include σ max ≤0.8σ γiel d (finite element stress constraint), number of counterweights ≤ N max Unbalanced phase correction angle ≤ 3°;

[0010] The counterweight scheme is rendered in a 3D visualization engine, and the σ is verified in real time using the finite element API. max When σ max ≤0.8σ γiel d. When the compliance progress bar shows a compliance rate of ≥100%, the counterweight plan will be implemented.

[0011] The system outputs the counterweight hole drilling positions, bolt specifications, torque, and hammer / impeller replacement list, which is pushed to the MES via OPCUA / RESTAPI; after construction, it automatically remeasures and corrects the vibration, forming a closed loop.

[0012] A further preferred embodiment of the present invention includes: the rule engine is built based on a decision tree or machine learning model, and includes a manual confirmation interface, allowing the operator to adjust the recommended target criteria.

[0013] In a further preferred embodiment of the present invention, the standard library stores standard parameter curves in JSON or XML format, and includes at least one of ISO 1940 G2.5-G40, ISO 10816 I-IV, API 610 bearing housing vibration limits, and ISO 8821 permissible unbalance of flexible rotors.

[0014] In a further preferred embodiment of the present invention: the 3D visualization engine employs any one or a combination of Unity3D, Unreal Engine, OpenGL, Cesium, and Three.js, and dynamically displays the U-shaped progress bar in a compliant manner. r / U perm The degree of compliance.

[0015] In a further preferred embodiment of the present invention: the finite element API calibration verifies the σ after the counterweight is calculated in real time. max and the material yield strength σ γiel d comparison, when σ max >0.8σ γiel The counterweight scheme is automatically iterated and optimized at time d.

[0016] This invention provides a system for implementing a virtual counterweight dynamic balancing method for rotating machinery based on multi-standard dynamic compliance, comprising:

[0017] Data acquisition module: used to acquire rotor vibration signals and phase signals, and calculate residual unbalance U. r ;

[0018] Equipment metadata management module: stores device type, rigid / flexible classification, speed range, and installation level parameters;

[0019] Standards library: Stores at least one standard parameter from ISO 1940 / 21940, ISO 8821, ISO 10816 / 20816, API 610 / 671, or GB / T9239;

[0020] Rule Engine: Automatically recommends target standards based on device metadata and real-time operating conditions, including decision tree or machine learning models and a manual confirmation interface;

[0021] Compliance assessment module: Comparison with U r with U perm Or A rms With V perm This triggers multi-objective optimization.

[0022] Multi-objective optimization module: Employs an improved NSGA-II algorithm, with J = 0.7·(U r / U perm )+0.3·ΣΔm i Generate a weight scheme for the objective function;

[0023] Finite element verification module: Real-time calculation of σ max And verify σ max ≤0.8σ γiel d;

[0024] 3D visualization module: Renders the counterweight scheme and displays a compliance progress bar;

[0025] MES Interface Module: Generates work orders and connects to the MES system via OPC UA / REST API to achieve closed-loop feedback.

[0026] The data acquisition module described above uses a combination of vibration sensors and photoelectric / magnetic encoders, with a sampling frequency ≥ 10 times the rotor speed frequency.

[0027] The beneficial effects of this invention are:

[0028] This invention constructs a dynamic matching system that includes multiple standards such as ISO, API, and GB / T. Through a rule engine / machine learning model, it automatically recommends standards based on equipment type and operating conditions, and combines this with a closed-loop manual confirmation process, which greatly reduces human judgment errors and solves the long-standing problem of lack of standard adaptation in the industry.

[0029] This invention renders the counterweight scheme in real time using a 3D visualization engine (Unity3D, etc.) and simultaneously calls the finite element API to perform stress constraints (σ_max≤0.8σ_yield), forming a closed-loop process of "residual imbalance calculation - multi-objective optimization - virtual simulation - safety verification". This transforms traditional offline trial weighting into online virtual compensation, enabling dynamic balancing to be completed with a single shutdown.

[0030] This invention employs an improved NSGA-II algorithm, with the objective function being to minimize U_r / U_perm (the degree of unbalance) and the total amount of counterweight (weights 0.7:0.3). It also introduces multi-dimensional conditions such as finite element stress constraints and restrictions on the number of counterweight blocks, which improves the efficiency by ≥50% compared to traditional single-objective optimization.

[0031] This invention integrates data acquisition, standard library, rule engine, optimization module, finite element verification, 3D visualization and MES interface to achieve full-process automation from vibration monitoring to work order execution, solving the problems of excessive manual intervention and delayed feedback in traditional processes. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the modular structure of a system for a virtual counterweight dynamic balancing method for rotating machinery based on multi-standard dynamic compliance. Figure 2 A schematic diagram of the ISO / API standard compliance assessment and NSGA-II optimization process. Detailed Implementation

[0034] To make the content of this invention easier to understand, the invention will be further described in detail below based on specific embodiments.

[0035] Example 1

[0036] This embodiment provides a method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance, specifically including the following steps:

[0037] The rotor vibration signal and phase signal are collected, and the result is obtained through formula U. r =k·A rms / ω 2 Calculate the residual unbalance U r , where k is determined by calibration experiments, and the phase signal is obtained through a photoelectric / magnetic grating encoder;

[0038] Input the equipment metadata and real-time operating conditions into the rule engine, and the rule engine will automatically select and recommend target standards from the standard library;

[0039] After manual confirmation, the permissible imbalance U is locked. perm Or vibration threshold V perm;

[0040] When U r >U perm Or the effective value of vibration A rms >V perm At that time, the counterweight mass Δm was generated based on the improved NSGA-II multi-objective optimization algorithm. i and phase φ i The objective function is J = w1·(U r / U perm )+w2·ΣΔm i Where w1:w2=0.7:0.3, the constraints include σ max ≤0.8σ γiel d (finite element stress constraint), number of counterweights ≤ N max Unbalanced phase correction angle ≤ 3°;

[0041] The counterweight scheme is rendered in a 3D visualization engine, and the σ is verified in real time using the finite element API. max When σ max ≤0.8σ γiel d. When the compliance progress bar shows a compliance rate of ≥100%, the counterweight plan will be implemented.

[0042] The system outputs the counterweight hole drilling positions, bolt specifications, torque, and hammer / impeller replacement list, which is pushed to the MES via OPCUA / RESTAPI; after construction, it automatically remeasures and corrects the vibration, forming a closed loop.

[0043] This embodiment provides a system for implementing a virtual counterweight dynamic balancing method for rotating machinery based on multi-standard dynamic compliance, such as... Figure 1 As shown, it includes:

[0044] Data acquisition module: used to acquire rotor vibration signals and phase signals, and calculate residual unbalance U. r ;

[0045] Equipment metadata management module: stores device type, rigid / flexible classification, speed range, and installation level parameters;

[0046] Standards library: Stores at least one standard parameter from ISO 1940 / 21940, ISO 8821, ISO 10816 / 20816, API 610 / 671, or GB / T9239;

[0047] Rule Engine: Automatically recommends target standards based on device metadata and real-time operating conditions, including decision tree or machine learning models and a manual confirmation interface;

[0048] Compliance assessment module: Comparison with U r with U perm Or A rmsWith V perm This triggers multi-objective optimization.

[0049] Multi-objective optimization module: Employs an improved NSGA-II algorithm, with J = 0.7·(U r / U perm )+0.3·ΣΔm i Generate a weight scheme for the objective function;

[0050] Finite element verification module: Real-time calculation of σ max And verify σ max ≤0.8σ γiel d;

[0051] 3D visualization module: Renders the counterweight scheme and displays a compliance progress bar;

[0052] MES Interface Module: Generates work orders and connects to the MES system via OPC UA / REST API to achieve closed-loop feedback.

[0053] The data acquisition module described above uses a combination of vibration sensors and photoelectric / magnetic encoders, with a sampling frequency ≥ 10 times the rotor speed frequency.

[0054] The aforementioned rule engine is built on decision tree or machine learning model and includes a manual confirmation interface, allowing operators to adjust the recommended target criteria. The rule engine is based on equipment type, rigidity / flexibility classification, speed range, installation level, and current vibration output candidate criteria.

[0055] The aforementioned standard library stores standard parameter curves in JSON or XML format, and includes at least one of the following: ISO 1940 G2.5-G40, ISO 10816 I-IV, API 610 Vibration Limits for Bearing Housings, and ISO 8821 Permissible Unbalance for Flexible Rotors.

[0056] The aforementioned 3D visualization engine uses any one or a combination of Unity3D, Unreal Engine, OpenGL, Cesium, and Three.js to dynamically display the U-shaped progress bar. r / U perm The degree of compliance.

[0057] The aforementioned finite element verification module calculates the σ after counterweighting in real time. max and the material yield strength σ γiel d comparison, when σ max >0.8σ γiel The counterweight scheme is automatically iterated and optimized at time d.

[0058] Based on the above solutions, the following examples are provided:

[0059] Example 1 (rigid rotor): Single-stage hammer crusher in cement plant, ISO1940 G6.3; U_r=2200g·mm→The system recommends ISO1940 template, and after optimization, Δm=160g@150°, the vibration value of the first test run is 1.2mm / s, and the compliance progress is 100%.

[0060] Example 2 (Industry Standard Switching): API610 petrochemical pump, n=2980rpm, A_rms=7.8mm / s → Rule engine prioritizes API610 vibration limit of 6mm / s; replace impeller dynamic balance block + counterweight on opposite side 25g@210°, vibration reduced to 3.2mm / s, progress bar shows 103% compliance.

[0061] Example 3 (Flexible Rotor): Flexible high-speed compressor, n = 18000rpm → rule engine switching ISO8821; the system calculates the residual imbalance and gives two sets of counterweights in the third and fifth correction planes, verifying σ_max 72MPa < 0.8σ_yield, compliance progress 102%.

[0062] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance, characterized in that: Specifically, the following steps are included: The rotor vibration signal and phase signal are collected, and the result is obtained through formula U. r =k·A rm s / ω 2 Calculate the residual unbalance U r , where k is determined by calibration experiments, and the phase signal is obtained through a photoelectric / magnetic grating encoder; Input the equipment metadata and real-time operating conditions into the rule engine, and the rule engine will automatically select and recommend target standards from the standard library; After manual confirmation, the permissible imbalance U is locked. perm Or vibration threshold V perm ; WhenU r >U perm Or the effective value of vibration A rms >V perm At that time, the counterweight mass Δm was generated based on the improved NSGA-II multi-objective optimization algorithm. i and phase φ i The objective function is J = w1·(U r / U perm )+w2·ΣΔm i Where w1:w2=0.7:0.3, the constraints include σ max ≤0.8σ γiel d (finite element stress constraint), number of counterweights ≤ N max Unbalanced phase correction angle ≤ 3°; The counterweight scheme is rendered in a 3D visualization engine, and the σ is verified in real time using the finite element API. max When σ max ≤0.8σ γiel d. When the compliance progress bar shows a compliance rate of ≥100%, the implementation of the counterweight plan is determined; The system outputs the counterweight hole drilling positions, bolt specifications, torque, and hammer / impeller replacement list, which is pushed to the MES via OPC UA / REST API; after construction, it automatically remeasures and corrects the vibration, forming a closed loop.

2. The method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance as described in claim 1, characterized in that: The rule engine is built on a decision tree or machine learning model and includes a manual confirmation interface, allowing operators to adjust the recommended target criteria.

3. The method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance as described in claim 1, characterized in that: The standard library stores standard parameter curves in JSON or XML format, and includes at least one of the following: ISO 1940 G2.5-G40, ISO 10816 I-IV, API 610 Vibration Limits for Bearing Housings, and ISO 8821 Permissible Unbalance for Flexible Rotors.

4. The method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance as described in claim 1, characterized in that: The 3D visualization engine uses any one or a combination of Unity3D, Unreal Engine, OpenGL, Cesium, and Three.js to dynamically display the U-shaped progress bar. r / U perm The degree of compliance.

5. The method for dynamic balancing of virtual counterweights for rotating machinery based on multi-standard dynamic compliance as described in claim 1, characterized in that: The finite element API calibration method calculates the σ after the counterweight in real time. max and the material yield strength σ γiel d comparison, when σ max >0.8σ γiel The counterweight scheme is automatically iterated and optimized at time d.

6. A virtual counterweight dynamic balancing system for rotating machinery based on multi-standard dynamic compliance, characterized in that, include: Data acquisition module: used to acquire rotor vibration signals and phase signals, and calculate residual unbalance U. r ; Equipment metadata management module: stores device type, rigid / flexible classification, speed range, and installation level parameters; Standards library: Stores at least one standard parameter from ISO 1940 / 21940, ISO 8821, ISO 10816 / 20816, API 610 / 671, or GB / T 9239; Rule Engine: Automatically recommends target standards based on device metadata and real-time operating conditions, including decision tree or machine learning models and a manual confirmation interface; Compliance assessment module: Comparison with U r with U perm Or A rms With V perm This triggers multi-objective optimization; Multi-objective optimization module: Employs an improved NSGA-II algorithm, with J = 0.7·(U r / U perm )+0.3·ΣΔm i Generate a weight scheme for the objective function; Finite element verification module: Real-time calculation of σ max And verify σ max ≤0.8σ γiel d; 3D visualization module: Renders the counterweight scheme and displays a compliance progress bar; MES Interface Module: Generates work orders and connects to the MES system via OPC UA / REST API to achieve closed-loop feedback.

7. A virtual counterweight dynamic balancing system for rotating machinery based on multi-standard dynamic compliance, characterized in that: The data acquisition module uses a combination of vibration sensor and photoelectric / magnetic encoder, with a sampling frequency ≥ 10 times the rotor speed frequency.

Images